Gas Storage Device

ABSTRACT

The present disclosure provides a gas storage device. In an embodiment, the gas storage device includes a cylinder with opposing ends. An endcap is present at each end. The cylinder and the endcaps form an enclosure. Each endcap includes a connector. A diaphragm is located in the enclosure. The diaphragm includes an annular sidewall. The device includes an inner chamber defined by an inner surface of the sidewall, and a storage space between an interior surface of the cylinder and an outer surface of the sidewall. A metal hydride composition is located in the storage space.

BACKGROUND

Hydrogen gas is the object of significant research as an alternate fuelsource to fossil fuels. Hydrogen is attractive because (i) it can beproduced from many diverse energy sources, (ii) hydrogen has a highenergy content by weight (about three times more than gasoline) and(iii) hydrogen's zero-carbon emission footprint—the by-products ofhydrogen combustion being oxygen and water.

However, hydrogen has physical characteristics that make it difficult tostore in large quantities without taking up a significant amount ofspace. Despite hydrogen's high energy content by weight, hydrogen has alow energy content by volume. This makes hydrogen difficult to store,particularly within the size and weight constraints of a vehicle, forexample. Another major obstacle is hydrogen's flammability and theconcomitant safe storage thereof.

Known hydrogen storage technologies directed to high pressure tanks withcompressed hydrogen gas and/or cryogenic liquid hydrogen storage haveshortcomings because the risk of explosion still exists. Theseapproaches require pressurized containers that are heavy and alsorequire high energy input—features that detract from commercialviability.

Metal alloy hydrogen storage is based on materials capable of reversiblyabsorbing and releasing the hydrogen. Metal alloy hydrogen storageprovides high energy content by volume, reduces the risk of explosion,and eliminates the need for high pressure tanks and insulation devices.Metal alloy hydrogen storage, however, struggles with low energy contentby weight.

The art recognizes the need for safe, reliable, compact, andcost-effective hydrogen storage technology. The art further recognizesthe need for continued development of metal alloy hydrogen storage.

SUMMARY

The present disclosure provides a gas storage device. In an embodiment,the gas storage device includes a cylinder with opposing ends. An endcapis present at each end. The cylinder and the endcaps form an enclosure.Each endcap includes a connector. A diaphragm is located in theenclosure. The diaphragm includes an annular sidewall. The deviceincludes an inner chamber defined by an inner surface of the sidewall,and a storage space between an interior surface of the cylinder and anouter surface of the sidewall. A metal hydride composition is located inthe storage space.

The present disclosure provides a gas storage assembly. In anembodiment, the gas storage assembly includes a first gas storage deviceand a second gas storage device. Each device includes a cylinder withopposing ends and an endcap at each end. The cylinder and the endcapsform an enclosure. Each endcap includes a connector. A diaphragm islocated in the enclosure. The diaphragm includes an annular sidewall. Aninner chamber is defined by an inner surface of the sidewall, and astorage space is located between an inner surface of the cylinder and anouter surface of the sidewall. A metal hydride composition is located ineach storage space. A connector of the first device is attached to aconnector of the second device. The attached connectors provide fluidcommunication between the enclosure of the first device and theenclosure of the second device.

The present disclosure provides a hydrogen charging station. Thehydrogen charging station includes at least one of the present gasstorage devices.

The present disclosure provides a hydrogen powered vehicle. The hydrogenpowered vehicle includes at least one of the present gas storagedevices.

The present disclosure provides a power pack. The power pack includes atleast one of the present gas storage devices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a gas storage device in accordance withan embodiment of the present disclosure.

FIG. 1B is a side elevation view of the gas storage device of FIG. 1 .

FIG. 2 is an exploded perspective view of the gas storage device inaccordance with an embodiment of the present disclosure.

FIG. 3 is a plan view of an inner surface of an endcap in accordancewith an embodiment of the present disclosure.

FIG. 3A is a sectional view of the endcap taken along line 3A-3A of FIG.3 .

FIG. 3B is a plan view of an inner surface of an endcap in accordancewith an embodiment of the present disclosure.

FIG. 3C is a sectional view of the endcap taken along line 3C-3C of FIG.3B.

FIG. 3D is an exploded perspective view of two endcaps and a tubularfilter in accordance with an embodiment of the present disclosure.

FIG. 3E is a sectional view of the endcaps and tubular filter of FIG.3D.

FIG. 4 is a plan view of a gasket in accordance with an embodiment ofthe present disclosure.

FIG. 4A is sectional view of the gasket taken along line 4A-4A of FIG. 4.

FIG. 5 is a perspective view of a diaphragm in accordance with anembodiment of the present disclosure.

FIG. 6 is a perspective view of another diaphragm in accordance with anembodiment of the present disclosure.

FIG. 7 is a sectional view of the gas storage device in accordance withan embodiment of the present disclosure.

FIG. 8 is a sectional view of the storage device of FIG. 7 during a gascharging procedure in accordance with an embodiment of the presentdisclosure.

FIG. 8A is a cutaway perspective view of a metal hydride compositionduring the gas charging procedure of FIG. 8 , in accordance with anembodiment of the present disclosure.

FIG. 8B is another cutaway perspective view of the metal hydridecomposition during the gas charging procedure of FIG. 8 , in accordancewith an embodiment of the present disclosure.

FIG. 9 is a sectional view of the storage device of FIG. 7 during a gasdischarging procedure in accordance with an embodiment of the presentdisclosure.

FIG. 9A is a cutaway perspective view of the metal hydride compositionduring the gas discharging procedure of FIG. 9 , in accordance with anembodiment of the present disclosure.

FIG. 9B is another cutaway perspective view of the metal hydridecomposition during the gas discharging procedure of FIG. 9 , inaccordance with an embodiment of the present disclosure.

FIG. 10 is a perspective view of two interconnected gas storage devicesin accordance with an embodiment of the present disclosure.

FIG. 10A is a sectional view of two interconnected gas storage devicestaken along line 10A-10A of FIG. 10 .

FIG. 10B is a schematic representation of the gas storage devicegenerating electricity, in accordance with an embodiment of the presentdisclosure.

FIG. 11 is a perspective view of a hydrogen charging station utilizingthe present gas storage device in accordance with an embodiment of thepresent disclosure.

FIG. 12 is a perspective view of a vehicle powered by the present gasstorage device in accordance with an embodiment of the presentdisclosure.

DEFINITIONS

The numerical ranges disclosed herein include all values from, andincluding, the lower value and the upper value. For ranges containingexplicit values (e.g., 1, or 2, or 3 to 5, or 6, or 7) any subrangebetween any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to7; 3 to 7; 5 to 6; etc.).

Unless stated to the contrary, implicit from the context, or customaryin the art, all parts and percents are based on weight, and all testmethods are current as of the filing date of this disclosure.

The term “composition,” as used herein, refers to a mixture of materialswhich comprise the composition, as well as the reaction products anddecomposition products formed from the materials of the composition.

The terms “comprising,” “including,” “having,” and their derivatives,are not intended to exclude the presence of any additional component,step or procedure, whether or not the same is specifically disclosed. Inorder to avoid any doubt, all compositions claimed through use of theterm “comprising” may include any additional additive, adjuvant, orcompound, whether polymeric or otherwise, unless stated to the contrary.In contrast, the term, “consisting essentially of” excludes from thescope of any succeeding recitation any other component, step orprocedure, excepting those that are not essential to operability. Theterm “consisting of” excludes any component, step or procedure notspecifically delineated or listed.

Density is measured by performing standard displacement tests for smallsolids.

Volume is measured in accordance with standard calculus integration inthree axes.

DETAILED DESCRIPTION

The present disclosure provides a gas storage device. In an embodiment,the gas storage device includes a cylinder with opposing ends. An endcapis attached to each cylinder end. The cylinder and the endcaps form anenclosure. Each endcap includes a connector. A diaphragm with an annularsidewall is located in the enclosure. The gas storage device includes aninner chamber defined by an inner surface of the sidewall. The devicealso includes a storage space between an interior surface of thecylinder and an outer surface of the diaphragm sidewall. A metal hydridecomposition is located in the storage space.

The present device stores a gas. Nonlimiting examples of suitable gassesfor storage in the present device include hydrogen, methane, ethane,propane, butane, hythane (hydrogen/methane), and combinations thereof.

In an embodiment, the present device stores hydrogen gas. Although thepresent disclosure is directed to hydrogen gas storage, it is understoodthat other gasses may be stored by way of the present device.

1. Cylinder

The gas storage device includes a cylinder with opposing ends. In anembodiment, a gas storage device 10 is provided and includes a cylinder12 as shown in FIGS. 1A, 1B, and 2 . The cylinder 12 is an annularstructure, or a hollow structure. The cylinder 12 has opposing ends. Thecross-sectional shape of the cylinder may be circular, elliptical, orpolygonal. The inner diameter of the cylinder may be uniform or theinner diameter of the cylinder may vary along the length of thecylinder.

In an embodiment, the cross-sectional shape of the cylinder 12 iscircular, or substantially circular, and the diameter of the cylinder 12is uniform, or otherwise constant, along its length as shown in FIGS.1A, 1B, and 2 .

Nonlimiting examples of suitable materials for the cylinder includemetal, polymeric material, nanomaterials, and combinations thereof.Nonlimiting examples of suitable metal for the cylinder includealuminum, aluminum alloy, copper, steel, stainless steel, andcombinations thereof. Nonlimiting examples of suitable polymericmaterial for the cylinder include carbon fiber, polyolefin,polycarbonate, acrylate, fiberglass, and Ultem, and combinationsthereof. The cylinder may be a combination of metal and polymericmaterial such as a metal liner thermoset in a polymeric resin, forexample.

In an embodiment, the cylinder 12 is composed of a heat conductivematerial. The heat conductive material promotes heat dissipation(cooling) during hydrogen charging and promotes warming during hydrogendischarge as will be described below. In this way, the cylinder bodyitself functions as a heat exchanger and the present gas storage deviceeliminates the need for a separate heat exchanger and/or a separatecoolant system. The structure and composition of the cylinder 12advantageously promotes energy efficiency, ease-of-use,ease-of-production, and reduction in weight for the device 10.

In an embodiment, the cylinder 12 is composed of aluminum, a heatconductive material.

In an embodiment, the cylinder 12 is composed of stainless steel, a heatconductive material.

The interior surface of the cylinder 12 can be smooth or fluted. In anembodiment, the cylinder 12 has a fluted interior surface 14 as shown inFIG. 2 . The term “fluted” or “fluting,” or “fluted surface,” and liketerms refers to a structure embodying a series of uniform and repeatinggrooves and peaks. The fluting can be any structure and/or configurationthat increases the surface area of the interior surface 12. Thelow-point of the groove and/or the high point of the peak may be pointedor may be curved. In an embodiment, the low-point and the high-point forrespective grooves and peaks for fluted interior surface 14 are curved,each low-point and/or high-point having a radius of curvature, Rc, from0.1 millimeter (mm), or 0.5 mm, or 1.0 mm, or 1.5 mm, or 2.0 mm, or 4.0mm, or 5.0 mm, or 6.0 mm, or 7.0 mm, or 8.0 mm, or 10 mm, or 20 mm, or50 mm, or 70 mm, or 90 mm to 100 mm, or 150 mm, or 200 mm.

In an embodiment, the Rc for the fluting is from 4.0 mm, or 6.0 mm to7.0 mm, or 8.0 mm.

2. Endcaps

At each end of the cylinder is a respective endcap. At least one endcapis releasably attached to its respective cylinder end, permitting accessto the cylinder interior. In an embodiment, one endcap is releasablyattachable to one cylinder end and the other endcap is permanentlyaffixed to, or is otherwise integral to, the other cylinder end. Thecylinder and the endcaps form an interior enclosure or enclosure 20shown in FIGS. 7, 8, and 9 .

In an embodiment, each endcap is releasably attached to a respectivecylinder end. The device 10 includes endcap 16 and an endcap 17 as bestshown in FIGS. 1A, 1B, and 2 . Each endcap 16, 17 is releasablyattachable to the cylinder 12 by way of attachment members. The materialof each endcap may be the same or different. The endcap material may bethe same as, or different than, the material of the cylinder aspreviously disclosed.

In an embodiment, the material of each endcap and the material of thecylinder is the same, the cylinder and each endcap composed of a heatconductive material.

Each endcap includes a respective connector. Endcap 16 includesconnector 18 and endcap 17 includes connector 19. Each connector 18, 19is a tubular conduit, each connector including a two-way valvepermitting through-flow fluid communication between the enclosure andthe external environment. The two-way valve permits gas (i.e., hydrogengas) to flow into the gas storage device. Each two-way valve alsopermits hydrogen gas to flow out of the device. A nonlimiting example ofa suitable two-way valve for each connector 18, 19 is a quick connectvalve with a pullback collar.

In an embodiment, each connector is centrally located on its respectiveendcap. The connectors 18, 19 define a central longitudinal axis Lthrough the device 10 as shown in FIGS. 1B and 7 .

In an embodiment, endcap 16 includes a pressure release valve 23 shownin FIGS. 1A, 3, 3A-3E, 7, 8 and 10A. Pressure release valve 23 allowsfor escapement of pressure to avoid unsafe buildup of pressure withingas storage device 10 and ensures the safe handling of metal hydridecomposition and pressurized hydrogen.

In an embodiment, the pressure release valve 23 releases, or otherwiseopens, when the pressure within cylinder 12 is greater than or equal to3447 kiloPascals (kPa) (500 pounds per square inch, psi).

In an embodiment, endcap 16 includes feet 25. Feet 25 protect connector18 when the device 10 is stood upright, supported by endcap 16. It isunderstood endcap 17 may have similar feet.

The exterior of each endcap may include a structure, such as a sheath(not shown) to protect each connector 18, 19. The sheath may be integralto the endcap. Alternatively, a sheath may be attached to eachrespective endcap to protect each connector against impact, drop, orother damage.

Each endcap 16, 17 includes a respective rim located on the interiorsurface of the endcap. The structure of the rim may be smooth(non-fluted) or may be fluted. The rim provides a continuous innerperimeter on an inner surface of the endcap.

One or both endcaps can include fluted structure, alone, or incombination with fluted surface 14 of the cylinder 12. In an embodiment,FIGS. 2, 3, and 3A show fluted rim 22 for endcap 16. The structure ofthe fluted rim 22 may or may not match the structure of the flutedinterior surface 14. In an embodiment, the structure of the fluted rim22 matches the structure of the fluted interior surface 14 of thecylinder 12. In other words, fluted rim 22 is configured to have (i) thesame number of flutes, (ii) the same low-point/high-point dimensions,and (iii) the same radius of curvature (when grooves/peaks are curved)as the fluted interior surface 14. It is understood that endcap 17 mayhave a similar rim structure. The rim 22 supports the diaphragm withinthe enclosure 20 as will be described below.

Each endcap includes a plurality of ports. FIGS. 2-3 show ports 24 forendcap 16. It is understood that endcap 17 has similar ports. The ports24 are arranged in a spaced-apart manner around the perimeter defined byrim 22. The ports permit fluid communication, or gas flow, between theinner chamber and the storage space of device 10 as will be describedbelow.

In an embodiment, each endcap 16, 17 is releasably attachable to thecylinder 12. Attachment members, a nonlimiting example of which arebolts 26, releasably attach endcaps 16, 17 to respective opposing endsof the cylinder 12 to form the enclosure 20. Suitable gaskets and/orO-rings are positioned between the cylinder ends and each endcapinterior surface to ensure an airtight (i.e., a hydrogen gas tight)seal. When the device 10 is in operation, the enclosure 20 is a closedvolume and an airtight volume.

3. Diaphragm

The device includes a diaphragm. The diaphragm is a tubular structurehaving an annular sidewall and opposing open ends. The sidewall may ormay not be fluted. The diaphragm may or may not have a uniform diameteralong its length. The diaphragm is made of a flexible and resilientmaterial. Nonlimiting examples of suitable material for the diaphragminclude polymeric material and metal. The diaphragm may or may not bepermeable to gas, such as hydrogen gas, for example. The diaphragm islocated in the enclosure, the sidewall extending the length of theenclosure, and the diaphragm defines an inner chamber and a storagespace.

In an embodiment, the device 10 includes a diaphragm 28 with a flutedsidewall 30 and opposing open ends as shown in FIGS. 2 and 5 . Thestructure and/or the configuration of the fluted sidewall 30 may thesame as, or different than, the structure or configuration of the flutedinterior surface 14 and/or the structure/configuration of the fluted rim22. In an further embodiment, the structure of the fluted sidewall 30matches the structure of the fluted interior surface 14 and thestructure of the fluted rim 22. In other words, fluted sidewall 30 isconfigured to have (i) the same number of flutes, (ii) the samelow-point/high-point dimensions, and (iii) the same radius of curvature(when grooves/peaks are curved) as the fluted interior surface 14 andthe fluted rim 22.

In an embodiment, diaphragm 28 is composed of a flexible polymericmaterial resistant to degradation (i.e., resistant to hydrogenembrittlement and/or resistant to metal hydride abrasion) and isimpermeable to hydrogen gas and is impermeable to water. Nonlimitingexamples of suitable flexible polymeric material for the diaphragminclude polypropylene (including polypropylene plastomer), polyethylene(including high density polyethylene, low density polyethylene, linearlow density polyethylene, and polyethylene elastomer), polyvinylchloride, polycarbonate/acrylonitrile butadiene styrene blend (PC/ABS),polylactic acid, natural rubber, synthetic rubber, polyphenylsulfone,and combinations thereof.

In an embodiment, the diaphragm 28 is composed of a polyethyleneelastomer with a Shore A hardness from 70, or 80 to 90.

Referring to FIGS. 2 and 7 , the diaphragm 28 is located in theenclosure 20. In an embodiment, the diaphragm 28 has a uniform diameteralong its length. The diaphragm 28 extends along the length of theenclosure 20. At each open end of the diaphragm is a flange 32. Eachflange 32 extends radially outward to cover, or otherwise to overlap, aportion of a respective cylinder end. The diaphragm 28 defines an innerchamber 34 and a storage space 36. More specifically, FIG. 7 shows theinner surface of the fluted sidewall 30, along with the inner surfacesof the endcaps 16, 17 define the inner chamber 34. The outer surface ofthe fluted sidewall 30 and the fluted interior surface 14 of thecylinder 12 (along with a portion of each endcap inner surface) definethe storage space 36.

In an embodiment, the enclosure has a diameter of length A and thediaphragm has a diameter (unflexed) of length B as shown in FIG. 7 . Thelength of diameter B (in centimeters, cm) is from 0.1 times (x), or 0.2x, or 0.3 x, or 0.4 x, or 0.5 x to 0.6 x, or 0.7 x, or 0.8 x, or 0.9 x,or 0.95 x the length of diameter A (in centimeters, cm).

In an embodiment, the device 10 has the following dimensions, DimensionsA, in the table below.

Dimensions A

diameter A (Fig. 7) 12.8 cm cylinder, outermost diameter 15.1 cm length(endcap to endcap, outermost surface) 17.7 cm

In an embodiment, one, some, or all of the components of Dimensions Acan be reduced by an amount from 10%, or 20%, or 40% to 50%, or 60%, or70%, or 80%, or 90%.

In an embodiment, one, some, or all of the components of Dimensions Acan be increased by an amount from 125%, or 150%, or 200%, or 300%, to400%, or 500%.

4. Storage Space and Metal Hydride Composition

The device includes a metal alloy located in the storage space. Themetal alloy is a metal hydride composition. Consequently, the deviceincludes a metal hydride composition located in the storage space. Themetal hydride composition contacts the inner surface of the cylinder andalso contacts the outer surface of the diaphragm. The direct contactbetween the metal hydride composition and the cylinder inner surfaceadvantageously contributes to the heat dissipation capability of thedevice—particularly during hydrogen charge.

The storage space may be partially filled (to allow for expansion of themetal hydrides) or completely filled with the metal hydride composition.The metal hydride typically exhibits and expansion from 5 vol % to 10vol % upon initial activation. Thus, when the storage space iscompletely filled with metal hydride composition, the volume of thestorage space and the volume of metal hydride composition will be usedinterchangeably.

In an embodiment, the device 10 includes storage space 36 with metalhydride composition 37 located therein as shown in FIGS. 2 and 7 . Thestorage space 36 is a closed volume and provides a donut-shapedcross-section shape for the metal hydride composition as shown in FIG. 2.

In an embodiment, the device 10 includes one, some, or all of thefollowing features (unflexed diaphragm):

(i) a storage space-to-enclosure volume ratio (in cubic centimeters, cc)from 0.3, or 0.4, or 0.5 to 0.6, or 0.7, or 0.8; and/or

(ii) a storage space-to-inner chamber volume ratio (in cc) from 0.5, or0.6, or 0.7, or 0.8 to 0.9, or 1.0; and/or

(iii) an inner chamber-to-enclosure volume ratio (in cc) from 0.5, or0.6 to 0.7, or 0.8; and/or

(iv) a storage space surface area (cm²)-to-storage space volume (cc)ratio from 0.4, or 0.5 to 0.6, or 0.7, or 0.8.

The form of the metal hydride composition 37 is a granular powder. Themetal hydride composition is a porous material. The metal hydridecomposition may or may not include a binding agent. In an embodiment,the metal hydride composition has a D50 particle size from 1.0 microns,or 1.5 microns, or 2.0 microns to 2.5 microns, or 3.0 microns, or 4.0microns, or 5.0 microns. The term “D50,” as used herein, is the medianparticle diameter such that 50% of the sample weight is above the statedparticle diameter.

In an embodiment, the metal hydride composition has a D50 particle sizefrom 1.5 microns to 2.0 microns.

Alternatively, the metal hydride composition is provided in a pluralityof discrete packets. The packets are composed of a gas permeablematerial. The discrete packets are inserted into the storage space 36 tofill the volume of the storage space.

In an embodiment, the metal hydride composition has the Formula (I):

AB_(5+X)

-   -   wherein    -   “A” is an element selected from the rare earth metals, yttrium,        mischmetal or a combination thereof; and    -   “B” is nickel and tin, or nickel and tin and at least a third        element selected from the elements of group IV of the periodic        table, aluminum, manganese, iron, cobalt, copper, titanium,        antimony, or a combination thereof. The value of X is 0, or is        greater than 0 and less than or equal to about 2.0.

The term “mischmetal” (abbreviated Mm) is a naturally occurring mixtureof rare earth elements (also known as “raw battery alloy”), andtherefore its use is more economic than combinations of pure elements. Atypical composition of mischmetal is approximately 21 percent La,approximately 57 percent Ce, approximately 15 percent Nd, approximately7 percent Pr, and approximately 1 percent other. Weight percent is basedon total weight of the mischmetal.

5. Gasket

In an embodiment, a gasket 38 is placed on each flange 32 to ensure anairtight seal between the cylinder ends and the endcaps 16, 17, as shownin FIGS. 2, 4, 4A, and 7 . Each gasket 38 includes a plurality of openseats 40, each seat 40 configured to hold a respective semi-permeablebarrier as shown in FIGS. 2, 4, and 4A. In an embodiment, gasket 38includes a fluted inner ring 42 that matches, or otherwise mates with,the fluted rim 22 of each respective endcap 16, 17. The seats 40 arearranged in a spaced-apart manner around the perimeter of the flutedinner ring 42. The seats 40 are spaced and configured to align withrespective ports 24 of the endcap.

The semi-permeable barrier is composed of a material that is permeableto gas (i.e., hydrogen gas) and impermeable to the metal hydridecomposition. Nonlimiting examples of suitable material for thesemi-permeable barrier include porous ceramic material, fiber, airstonematerial, fine ceramic/glass bead blend, fine metal filter (1.0, or 1.5,or 2.0, or 3.0 to 4.0, or 5.0 micron pore size), and combinationsthereof. In an embodiment, the semi-permeable barrier is a disc 44 a ofa porous ceramic material. The porous ceramic material is permeable tohydrogen gas and impermeable to the metal hydride composition 37.

In an embodiment, each endcap 16, 17 is subsequently placed on arespective gasket 38. Each endcap 16, 17 is positioned so that each port24 is aligned with a respective seat/disc 40, 44 a. The diaphragm 28 isimpermeable to the metal hydride composition 37. Each seat/disc 40, 44a, and port 24 provides fluid communication between the storage space 36and the inner chamber 34 while simultaneously retaining the metalhydride composition 37 within the storage space 36. Hydrogen gas flowsfreely between the storage space 36 and the inner chamber 34 vis-à-visthe ports/seat/disc arrangement. The metal hydride composition 37 isblocked from leaving the storage space 36. In this way, the device 10prevents (vis-à-vis the port/seat/disc configuration), passage of metalhydride particles from the storage space into the inner chamber andsimultaneously permits flow of hydrogen between the storage space andthe inner chamber.

Placement of each endcap onto its respective cylinder end brings eachendcap rim 22 into friction fit with the inner surface of the diaphragmsidewall 30. Securement of the endcaps 16, 17 to the cylinder 12sandwiches the gasket 38 and sandwiches the flange 32 between the endcapinterior and the cylinder end. At the same time, the endcap rim 22 abutsthe inner sidewall surface to provide rigid support to the diaphragmends. In this way, the diaphragm 28 is securely positioned within theenclosure 20 to define, or otherwise to form, two discrete areas (theinner chamber 34 and the storage space 36) within the enclosure 20.Moving from the exterior to the interior of the device, FIG. 7 shows thefollowing configuration:endcap(17)/O-ring(O)/gasket(38)/flange(32)/cylinder end.

In an embodiment, a semi-permeable membrane, such as disc 44 b of porousceramic material is operatively connected to each connector 18, 19 andoperatively connected to the pressure release valve 23 as shown in FIGS.3, 3A, and 7 . The disc 44 b permits hydrogen flow into/out of thedevice 10 and prevents metal hydride composition flow from device 10.

In an embodiment, the device 10 includes diaphragm 128 as shown in FIG.6 . Diaphragm 128 includes fluted sidewall 130 and opposing open ends.The structure of the fluted sidewall 130 may match, or may not match,the structure of the fluted interior surface 14 as discussed above. Ateach open end of the diaphragm 130 is a flange 132. The flange 132includes a plurality of open seats 140. Each seat 140 is configured tohold, or otherwise to retain, a semi-permeable barrier, such as disc 144a of porous ceramic material. The diaphragm 130 with discs 144 aintegrated in the flange may be used as a replacement for, or otherwisemay eliminate, the use of gasket 38 in the device 10.

6. Gas Charge

FIGS. 8, 8A, and 8B depict gas charging of the device 10. Hydrogen gasintroduced through one or both connectors is absorbed and adsorbed bythe metal hydride composition. The combined absorption and adsorption ofhydrogen atoms by the metal hydride composition is hereafter referred toas “hydrogen capacity.” Hydrogen gas under pressure is introduced intothe inner chamber by way of a connector, such as male connector 19 shownby arrows C in FIG. 8 . The pressurized hydrogen gas flows through theconnector and flows through the disc 44 b of porous ceramic material(semi-permeable membrane) and into the inner chamber 34. From the innerchamber 34, gas flows through ports 24, through the discs 44 a and intothe storage space 36.

In an embodiment, hydrogen gas is introduced into the device 10 at apressure (psi in parentheses) from 55 kPa (8), or 69 kPa (10), or 138kPa (20), or 172 kPa (25), or 207 kPa (30), or 241 kPa (35), 276 kPa(40), or 345 kPa (50), or 689 kPa (100), or 1388 kPa (200) to 2086 kPa(300), or 2413 kPa (350), or 2758 kPa (400).

In an embodiment, hydrogen gas is introduced into the device 10 at apressure (psi in parentheses) from 345 kPa (50), or 1387 kPa (200) to2086 (300), or 2758 (400).

The diaphragm is made from a flexible and resilient material. Thediaphragm is able to expand radially inward as the metal hydridecomposition loads, or otherwise saturates, with hydrogen gas. Thediaphragm is flexible, permitting contraction radially outward ashydrogen is discharged from the device.

The metal hydride composition 37 expands volumetrically as hydrogencharging proceeds. The diaphragm is a resilient flexible materialpermitting flex, or expansion of, the storage space 36 during hydrogencharge. The expansion pressure, shown by arrows D in FIG. 8 , impartedby the expanding bed of metal hydride composition 37 impinges upon thefluted sidewall 30 of diaphragm 28, flexing the sidewall inward. Eachdiaphragm end is securely fastened by way of the “sandwich”configuration between the endcaps and the cylinder ends as previouslydisclosed. The diaphragm ends are held in place, permitting the flutedsidewall 30 (made of resilient and flexible material) to flex radiallyinward, and as hydrogen capacity increases, the diaphragm 28simultaneously maintains a barrier between the storage space 36 and theinner chamber 34.

FIG. 8A shows the hydrogen gas migrating into the metal hydridecomposition 37 for adsorption/absorption therein. The peaks of thefluted sidewall 30 may mate with, or may be offset with, the peaks ofthe fluted interior surface 14. In either configuration (mated oroffset), the fluted sidewall 30 and the cylinder fluted interior surface14 form a plurality of parallel columns 46, in the storage space 36.Each column 46 is circular, or substantially circular, incross-sectional shape. Bounded by no particular theory, Applicantdiscovered the fluting improves hydrogen gas charging of the device 10.The fluting works synergistically to form a series of parallel, orsubstantially parallel, cylindrical columns 46 within the storage space36. The cylindrical cross-sectional shape of the columns 46 directs, orotherwise guides, the hydrogen gas in a helical flowpath E, in FIG. 8A.

In an embodiment, the diaphragm 28 is installed into the enclosure 20 sothat the grooves and peaks of the fluted sidewall 30 mate, or otherwisealign with, the respective grooves and peaks of the fluted interiorsurface 14 to form columns 46.

The fluting increases surface area contact between the gas and the metalhydride composition and simultaneously helically percolates the gasincreasing contact time and increasing surface area contact. Thisadvantageously increases hydrogen adsorption and absorption onto/intothe individual particles of the metal hydride composition. Inparticular, the helical flowpath E enables the hydrogen gas to graduallypercolate through particle bed of the metal hydride composition 37. Thehelical flowpath E (i) keeps the metal hydride particles in motion todecrease hydrogen adsorption/absorption time, (ii) prevents clumping oragglomeration of the metal hydride composition, (iii) increases thedistance each hydrogen molecule travels through the particle bed ofmetal hydride composition 37, (iv) improves the mobility of the hydrogenmolecules through the metal hydride composition, and (v) a combinationof (i), (ii), (iii), and (iv). The configuration of each column 46 alsoincreases the contact volume interface between a given hydrogen moleculeand the particles of metal hydride composition. Applicant discoveredthat the fluting (fluted interior surface 14 and fluted sidewall 30)leads to (vi) a faster rate of hydrogen adsorption/absorption, (vii) anincrease in hydrogen adsorption/absorption volume, (viii) increasedsurface area for improved cooling during gas charging, and (ix)increased surface area for improved heating during gas discharge.

In an embodiment, the device 10 has a hydrogen capacity from 60 gramsper liter (g/L), or 70 g/L, or 80 g/L, or 90 g/L, or 100 g/L, or 130g/L, or 150 g/L, or 170 g/L, or 190 g/L to 200 g/L, or 230 g/L, or 250g/L.

Hydrogen charging of the metal hydride composition is an exothermicreaction. The heat generated from the charging is dissipated through thecylinder 12 as shown by arrows F of FIG. 8B. Applicant discovered thatplacement of the metal hydride composition in direct contact with thefluted interior surface promotes heat dissipation through the cylinder.Bounded by no particular theory, it is believed that the fluted interiorsurface 14 of the cylinder 12 increases the surface area therebyincreasing the heat dissipation capacity of the cylinder. In this way,the present device 10 avoids, or otherwise eliminates, the need for acoolant system because the cylinder body itself functions as a heatexchanger. Thus, in an embodiment, the present device 10 is void of, oris otherwise free of, a coolant system.

The metal hydride composition 37 can store from 2%, or 5%, or 7% to 10%,or 15% or 20% of its own weight in hydrogen at room temperature. By wayof example, if the storage space 36 contains 1 kg of metal hydridecomposition, the metal hydride composition can contain from 20 g to 200g of hydrogen.

7. Vibration Device

The process of charging the device 10 with gas may also include one,some, or all of the following techniques: vibrational loading ofhydrogen gas into the device, and/or percussive loading of hydrogen gasinto the device.

In an embodiment, pressurized hydrogen gas is introduced into the device10. The hydrogen gas is introduced through connector 18 and/or connector19 into the enclosure 20 at a pressure (psi in parentheses) from 55 kPa(8), or 69 kPa (10), or 138 kPa (20), or 172 kPa (25), or 207 kPa (30),or 241 kPa (35), 276 kPa (40), or 345 kPa (50), or 689 kPa (100), or1388 kPa (200) to 2086 kPa (3000, or 2413 kPa (350), or 2758 kPa (400).

In an embodiment, a vibration device imparts a vibrational force to thepressurized hydrogen gas and to the metal hydride composition during gascharging. A “vibration device,” as used herein, is a device thatprovides periodic back-and-forth, or oscillating motion, to a structure.Nonlimiting examples of suitable vibration devices include solenoid,microdrive, vibration motor, linear resonant actuator, piezoelectricdrive, vibration platform, and any combination thereof. Bounded by noparticular theory, Applicant discovered that applying a vibration forceupon the device 10 during gas charging improves and promotes thehydrogen capacity of the metal hydride composition. Resonation of themetal hydride composition by way of percussive force and/or vibrationalforce yields a super-saturation of hydrogen solubility in the metalhydride composition, and in nickel/tin-based metal hydride compositionsin particular.

In an embodiment, the vibration device is an internal component of thedevice 10. The device 10 includes an endcap 116 as shown in FIGS. 3B and3C. Endcap 116 includes a connector, 118 (with disc 144 b of porousceramic material), a rim 122, and ports 124 as previously disclosed. Theendcap 116 includes a structure 126 configured to house a vibrationdevice, such as a solenoid, for example. The vibration device imparts avibrational force and/or a percussive force on the hydrogen gas and themetal hydride composition during gas charging. In a further embodiment,the vibration device frequency is adjusted to vibrate at the resonancefrequency of the metal hydride composition. Although FIGS. 3B and 3Cdepict endcap 116, it is understood that the device 10 may includeanother endcap 117 (not shown) with structure to house a vibrationdevice.

In an embodiment, the vibration device is a component that is externalto the device 10. The vibration device can be coupled to, or otherwiseoperatively connected to, the exterior of the device 10. The vibrationdevice imparts a vibrational force and/or a percussive force upon thehydrogen gas and the metal hydride composition as described above. Anonlimiting example of an exterior vibration device is a vibrationplatform (not shown) upon which the device 10 is placed during theintroduction of the pressurized hydrogen gas into the device.

Regardless whether the vibration device is internal or external to thedevice 10, the vibrational and/or the percussive force during hydrogencharging imparts a resonation of the metal hydride composition whichexpands the interstitial spaces of the metal hydride lattice structureto super-saturate hydrogen solubility within the metal hydridecomposition.

The charged device 10 provides one, some, or all of the followingproperties:

(i) solid-storage hydrogen storage that is non-explosive; and/or

(ii) completely reversible system (charge/discharge); and/or

(iii) no memory effect, dischargeable at 100% where power retrieval andenergy storage are uncoupled: and/or

(iv) years of maintenance-free operation; and/or

(v) no loss of hydrogen capacity; and/or

(vi) an internal pressure (psi in parentheses) from greater than 0 (>0),or 34 kPa (5), or 207 kPa (30), or 276 kPa (40), or 345 kPa (50), or 689kPa (100) to 1388 kPa (200), or 2086 kPa (300), or 2758 kPa (400).

8. Gas Discharge

Once charged, device 10 is ready to deliver hydrogen gas. One or bothconnectors can be connected to a gas outlet. Referring to FIGS. 9, 9A,and 9B, connector 18 is connected to a gas outlet. It is understood thatconnector 19 can be connected to a gas outlet in a similar manner. Whenthe gas outlet is opened, hydrogen gas, shown by outward flow of gas,arrows G, flows from storage chamber 36, through discs 44 a, throughports 24, through the inner chamber 34 through connector 18, and out ofthe device 10. When the gas outlet is opened, the flexed sidewall of thediaphragm 28 contracts (outward) towards its rest position and impingesupon the bed of metal hydride composition 37, as shown by arrows H. Theforce imparted by the contracting sidewall of the diaphragm 28 continuesthe pressurized flow of hydrogen gas from the metal hydride composition37, through discs 44 a, through ports 24, into the inner chamber 34, andout of connector 18.

Bounded by no particular theory, it is believed that the reciprocatingfluting structure between the fluted interior surface 14 and the flutedsidewall 30 and resultant columns 46 cause the hydrogen gas to exit themetal hydride composition 37 in a helical flowpath I as shown in FIG.9A. The helical flowpath I of the hydrogen molecules promote fulldissociation of hydrogen from the lattice structure of the metal hydridecomposition. The helical flowpath I keeps the particles of the metalhydride composition motile and free from clumping/agglomeration. Theincreased surface area provided by the fluted structures (cylinderinterior surface, diaphragm sidewall, endcaps) promotes desorption byenabling the device 10 to transfer ambient external heat into thecylinder interior.

Hydrogen discharge from the device 10 is an endothermic reaction. Thebody of the cylinder 12 functions as a heat exchanger to transfer heatfrom the ambient environment into the enclosure 20 as shown by arrows Jin FIG. 9B. In an embodiment, the metal hydride composition has aendothermic hydrogen release enthalpy in the range from 20-30 kilojoules (kj)/(mol H₂).

The diaphragm has several functions. First, the diaphragm 28 is abarrier between the storage space 36 and the inner chamber 34. Thediaphragm 28 prevents metal hydride composition 37 in the storage space36 from entering the inner chamber 34. Second, the diaphragm contributesto hydrogen loading. As the metal hydride composition becomes saturated,or super-saturated, with hydrogen molecules, the volume of the metalhydride composition increases flexing the fluted sidewall 30 radiallyinward. Third, the diaphragm contributes to hydrogen discharge. Aspreviously, mentioned, the diaphragm imparts a positive pressure on thesaturated metal hydride composition 37 in the storage space 36.

In an embodiment, a semi-permeable material extends through theenclosure of the device and between the connectors. The semi-permeablematerial may be any semi-permeable material disclosed above that permitshydrogen flow while preventing flow of the particles of the metalhydride composition. FIG. 3C shows an exploded view of endcap 116 andendcap 117, each endcap 116, 117 having structure 126. Structure 126 iscapable of being configured to house a vibration device, as disclosedabove. A tubular filter 60 extends through the structure 126 of eachendcap 116, 117. The tubular filter 60 is composed of a semi-permeablematerial such as a metal filter material having a pore size from 1micron to 2 microns. The tubular filter 60 is permeable to hydrogen gasand impermeable to the metal hydride particles. O-rings 62 are locatedat each end of the tubular filter 60 to provide an airtight seal betweenthe tubular filter 60 and each endcap 116, 117. The O-rings 62compressively hold the tubular filter 60 in place when the endcaps 116,177 and secured to the cylinder 12. As shown in FIG. 3E, the tubularstructure 60 extends from connector 119 through endcap 117, throughendcap 116, and to connector 118. Tubular filter 60 prevents egress ofmetal hydride particles from the device 10. Endcap 116 includes pressurerelease valve 123 and disc 144 b of ceramic material. It is understoodthat tubular filter 60 can be used with other endcap structures, such asendcaps without structure 126, as shown in FIG. 10A.

9. Interconnect

Referring to FIGS. 10 and 10A, two or more devices 10 may beinterconnected. Interconnection may occur during (i) gas charge, (ii)gas discharge, and (iii) both (i) and (ii). In an embodiment, femaleconnector 18 of device 10 b is attached to male connector 19 connectorof device 10 a in male-female connection, placing the enclosure 20 ofthe device 10 b into fluid communication with the enclosure 20 of device10 a.

Although FIGS. 10, 10A show two devices connected together, itsunderstood that 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10, or50, or 100, or 1000 devices or more may be interconnected.

FIGS. 10, 10A show the devices interconnected in series. A single lineof interconnected devices (“in series” interconnect, as shown in FIGS.10A and 10B) increases the run time of the devices but does not increasethe hydrogen flow rate. Interconnected devices 10 a and 10 badvantageously increase the hydrogen run time compared to the device 10a or device 10 b alone.

The devices may also be interconnected in parallel. Multiple devicesthat are interconnected “in parallel” increases the hydrogen flow rate,and provides the ability to deliver more hydrogen per minute (litersH₂/min).

The devices may also be interconnected both in series and in parallel.Multiple lines (in series interconnect of devices) are interconnected inparallel to (i) increase the hydrogen delivery run time and (ii) also toincrease the hydrogen flow rate.

In an embodiment, a manifold 200 supports the interconnected devices 10a/10 b and provides a platform and structure for delivering hydrogen gasfrom 1, or 2, or more devices. The manifold 200 includes tubing 202 forconnecting to a connector of a gas storage device to a control unit 210.The control unit 210 includes suitable flow regulators and valves todeliver the hydrogen at pressure suitable for the end application. In anembodiment, the control unit 210 includes a fuel cell to convert thehydrogen gas into electricity and power an electrical load, representedby light 212.

The size and capacity of the present gas storage device may be scaledfor the target application. FIG. 10B shows interconnected devices 300 a,300 b, 300 c, 300 d. The devices 300 a-d are constructed at a volume toprovide hydrogen gas for conversion into electricity energy withsufficient kilowatt/hours (kW/h) for powering the electrical load of adwelling such as building 302, of FIG. 10B. As such, the present gasstorage device may be configured in a modular manner.

The present device 10 may also be scaled to a smaller volume suitable topower consumer electronic devices such as computers, cameras, and thelike. The cooling effect (endothermic reaction) that occurs duringhydrogen discharge of the device 10 may be used to cool other componentsof the consumer electronic device by placing the device 10 proximate tocomponents that generate heat.

10. Hydrogen Charging Station

In an embodiment, the present gas storage device is a component of ahydrogen charging station as shown in FIG. 11 . A “hydrogen chargingstation,” is an assembly that stores hydrogen, and enables delivery ofthe hydrogen for filling hydrogen powered vehicles. A hydrogen chargingstation can be located along a road (similar to, or as part of, aconventional gas station), (ii) at an industrial site, and (iii) acombination of (i) and (ii). A “hydrogen powered vehicle” is a vehiclethat uses hydrogen gas as an energy source. Hydrogen gas as an energysource in a vehicle can be in the form of (i) the combustion of hydrogengas in an combustion engine or the like, (ii) conversion of hydrogen gasinto electricity by way of a fuel cell (also known as a “hydrogen fuelcell vehicle”), and (iii) a combination of (i) and (ii). Nonlimitingexamples of vehicles that can be powered by hydrogen, and thus can be ahydrogen powered vehicle include cars, trucks, motorcycles, scooters,forklifts, wheelchairs, trains, aircraft, boats, drones, helicopters,rockets, missiles, spacecraft, ships, submarines, torpedoes, and anycombination thereof.

In an embodiment, a hydrogen charging station 400 is provided andincludes a high pressure tank 402, a pressure converter unit 404, andone or more gas storage devices 410. The gas storage devices 410 may beany gas storage device as previously disclosed herein. The gas storagedevices 410 are interconnected as previously disclosed above. In anembodiment, the gas storage devices 410 are interconnected both inseries and in parallel as shown in FIG. 11 . Piping 412 places the gasstorage devices 410 in fluid communication with the converter unit 404.Piping 412 also places the converter unit 404 in fluid communicationwith high pressure tank 402.

The hydrogen gas is stored in the gas storage devices 410 at lowpressure. “Low pressure” is from 34 kPa (5 psi) to 2758 kPa (400 psi).Upon activation, the pressure converter unit 404 draws low pressurehydrogen from the gas storage devices 410, and pressurizes, or otherwiseconverts the low pressure hydrogen to high pressure hydrogen. “Highpressure” is from 55,159 kPa (8,000 psi) to 110,316 kPa (16,000 psi).Nonlimiting examples of suitable technologies for the pressure converterunit 404 includes a turbo inflator, a Venturi tube device, a procharger,and any combination thereof.

The pressure converter unit 404 delivers the high pressure hydrogen tothe high pressure tank 402. Once filled with high pressure hydrogen, ahose 414 is used to fill a hydrogen powered vehicle, such as hydrogenpowered car 416 as shown in FIG. 11 . The hose 414 delivers highpressure hydrogen to the vehicle high pressure tank 418.

In an embodiment, the pressure converter unit 404 draws low pressurehydrogen from the gas storage devices 410 and rapidly converts the lowpressure hydrogen to high pressure hydrogen. The devices 410interconnected in series and in parallel provide a large amount ofhydrogen gas to pressure converter unit 404 for rapid conversion to highpressure hydrogen. The pressure converter unit 404 converts and delivershigh pressure hydrogen to the high pressure tank 402 in a duration from10 seconds, or 20 seconds, or 30 seconds to 60 seconds, or 120 seconds,or 240 seconds, or 360 seconds, 480 seconds, or 600 seconds.

One, some, or all of the components of the hydrogen charge station 400may be above ground or may be underground. In an embodiment, the highpressure tank 402 is above ground and the pressure converter unit 404and the gas storage devices 410 are underground. The gas storage devices410 may be charged by way of inlet 420.

Once filling is complete, the hydrogen charge station 400 switches todwell mode. In dwell mode, any remaining high pressure hydrogen in thehigh pressure tank 402 is either vented or drawn into the pressureconverter unit 404 which re-charges the gas storage devices 410 with theunused high pressure hydrogen. In this way, the high pressure tank 402holds high pressure hydrogen only during active filling of a hydrogenpowered vehicle, thereby reducing the risk of explosion of the highpressure tank 402.

11. Hydrogen Powered Vehicle

The present disclosure provides a hydrogen powered vehicle wherein thepresent gas storage device provides power to the hydrogen poweredvehicle. In other words, the present gas storage device is a componentof a vehicle. The vehicle powered by the present gas storage device canbe any hydrogen powered vehicle as disclosed above. The power providedto the vehicle by the present gas storage device can be (i) hydrogencombustion, (ii) electrical power (via a hydrogen fuel cell) and (iii)and a combination of (i) and (ii).

In an embodiment, the present gas storage device is used to power acombustion engine 500 as shown in FIG. 12 . Suitable tubing 502 connectsone or more of the present gas storage devices 510 to the combustionengine 500. The hydrogen gas discharged from gas storage devices 510 isburned directly in the combustion engine 500. Tubing 502 can alsodeliver the hydrogen gas from the gas storage devices 510 to a fuel cell504 to generate electricity. The combustion engine can be a pistonengine, a gas turbine, a jet engine, a rocket engine, and anycombination thereof.

In an embodiment, the combustion engine is a component of a hydrogenpowered vehicle, such as a hydrogen powered automobile 550 shown in FIG.12 . One or more devices 510 are interconnected in series and/or inparallel. The devices 510 each has an energy density per unit masssuitable to power the vehicle. This combination of properties makes thepresent hydrogen gas storage device well-suited for vehicle applicationswhere volume density is a primary concern. When one or more of thedevices 510 is depleted, it is exchanged, or otherwise replaced with, afully charged device 510 a.

12. Power Pack

The present disclosure provides power pack. In an embodiment, the powerpack includes one or more of the present gas storage devices operativelyconnected to a fuel cell. The power pack also includes connectors (suchas wires, for example) to operatively connect the power pack to anelectrical load. In this way, the power pack is an electrical generatorand can be adapted to power myriad electrical loads.

The size, shape, and power output (i.e., number of gas storage devices)of the power pack can be tailored to accommodate the target application.Nonlimiting examples of electrical loads that can be powered by thepower pack include dwellings, buildings, consumer appliances, consumerelectronics, lighting units, heating units, vehicles, and anycombination thereof.

In an embodiment, the power pack is portable. The power pack can includea housing with a handle, enabling a person to hand-carry the power pack.

In an embodiment, the power pack is rechargable. Replacing or exchanging(or swapping) a power pack's depleted gas storage device(s) with acharged, or fully charged, gas storage devices recharges the power packand enables the power pack to provide additional electrical power.Exchange of gas storage devices can occur while the power pack isdelivering electricity thereby enabling the power pack to providecontinuous electrical power.

In an embodiment, the power pack is installed into a vehicle. Thevehicle may be a conventional vehicle. Once configured with the powerpack the vehicle becomes a hydrogen powered vehicle. The power pack maybe the primary power source or the power pack may be an auxiliary powersource for the vehicle.

The present power pack finds particular application to the tractionmarket (from forklifts to wheelchairs). The present power pack can beinstalled in conventional wheelchairs and/or in forklifts to provideprimary electric power or auxiliary electric power.

The power pack finds particular application to the electric vehiclemarket where range anxiety is a concern. In an embodiment, the powerpack is installed in an electric car (such as in the trunk, for example)and operatively connected to the electric car's power system. When themain battery of the electric car is depleted or otherwise reaches apre-determined depletion threshold, the power system switches to thepower pack and draws auxiliary electrical power from the fuel cell, thefuel cell fed hydrogen gas from the gas storage device. The power systemsignals the operator (via dashboard signal, for example) that thevehicle is operating on auxiliary power.

In an embodiment, the power pack provides the electric car withsufficient auxiliary electrical power to travel a distance from 5kilometers (km), or 10 km, or 20 km, or 30 km or 40 km, to 50 km, or 60km, or 70 km, or 80 km, or 90 km, or 100 km, or 125, or 150 km. Thepower pack in the electric car provides emergency or back up electricalpower. In this way, the power pack can reduce, or eliminate, rangeanxiety for operators of electric vehicles by providing auxiliaryelectric power upon depletion of the vehicle's battery. Once depleted,the gas storage device(s) are exchanged with charged, or fully charged,gas storage devices.

It is specifically intended that the present disclosure not be limitedto the embodiments and illustrations contained herein, but includemodified forms of those embodiments including portions of theembodiments and combinations of elements of different embodiments ascome within the scope of the following claims.

1-20. (canceled)
 21. A gas storage device comprising: a cylindercomprising a sidewall and opposing first and second ends, a first endcapat the first end and a second endcap at the second end, wherein thecylinder and the first and second endcaps form an enclosure, and whereinan interior surface of the sidewall is fluted; at least one of the firstendcap and the second endcap comprising a connector; a diaphragm in theenclosure; an inner chamber circumscribed by an inner surface of thediaphragm; a storage space between the interior surface of the sidewallof the cylinder and an outer surface of the diaphragm; and a metal alloycomposition located in the storage space.
 22. The gas storage device ofclaim 21, wherein the metal alloy composition stores hydrogen gas. 23.The gas storage device of claim 22, wherein the diaphragm is cylindricaland comprises a diaphragm sidewall.
 24. The gas storage device of claim21, wherein the diaphragm is cylindrical and comprises a diaphragmsidewall, opposing ends, a first flange located at a first end of thediaphragm sidewall, and a second flange located at a second end of thediaphragm sidewall.
 25. The gas storage device of claim 24, wherein thediaphragm sidewall is fluted.
 26. The gas storage device of claim 25,wherein peaks and grooves of the fluted diaphragm sidewall formcylindrical channels with respective peaks and grooves of the flutedinterior surface of the sidewall of the cylinder.
 27. The gas storagedevice of claim 24, wherein the diaphragm is permeable to hydrogen gas.28. The gas storage device of claim 24, further comprising: a firstgasket located between the first endcap and the first end of thecylinder, the gasket comprising a plurality of seats, each seat holdinga semi-permeable membrane; wherein an inner surface of the first endcapcomprises a plurality of endcap ports; wherein each semi-permeablemembrane is aligned with a respective endcap port; and wherein theendcap ports and the semi-permeable membranes provide fluidcommunication between the inner chamber and the storage space.
 29. Thegas storage device of claim 24, wherein an inner surface of the firstendcap comprises a plurality of endcap ports; wherein the first flangecomprises a plurality of seats, each seat holding a semi-permeablemembrane; wherein each semi-permeable membrane is aligned with arespective endcap port; and wherein the endcap ports and thesemi-permeable membranes provide fluid communication between the innerchamber and the storage space.
 30. The gas storage device of claim 21,further comprising a semi-permeable membrane coupled to the connector ofthe at least one of the first endcap and the second endcap.
 31. The gasstorage device of claim 21, further comprising a valve in the connectorof the at least one of the first endcap and the second endcap.
 32. Thegas storage device of claim 21, further comprising a vibration device.33. The gas storage device of claim 22, wherein the vibration device isone of an actuator, a solenoid, a ram head, a motor, and a piezoelectricmaterial.
 34. The gas storage device of claim 21, further comprising: asecond gas storage device coupled to the gas storage device, the secondgas storage device comprising: a cylinder comprising a sidewall andopposing first and second ends, a first endcap at the first end and asecond endcap at the second end of the cylinder, wherein the cylinderand the first and second endcaps form an enclosure, and wherein aninterior surface of the sidewall is fluted; at least one of the firstendcap and the second endcap of the second gas storage device comprisinga second connector, the second connector coupled to the connector of thegas storage device; a diaphragm in the enclosure; an inner chambercircumscribed by an inner surface of the diaphragm; a storage spacebetween the interior surface of the sidewall of the cylinder and anouter surface of the diaphragm; and a metal alloy composition located inthe storage space.
 35. A hydrogen charging station comprising the gasstorage device and the second gas storage device of claim
 34. 36. A gasstorage device comprising: a cylinder comprising a sidewall, a firstendcap, and a second endcap that form an enclosure, wherein an interiorsurface of the sidewall comprises grooves; at least one of the firstendcap and the second endcap comprising a connector; a diaphragm in theenclosure; an inner chamber circumscribed by an inner surface of thediaphragm; a storage space between the interior surface of the sidewallof the cylinder and an outer surface of the diaphragm; and a metal alloycomposition located in the storage space.
 37. The gas storage device ofclaim 36, wherein the metal alloy composition stores hydrogen gas. 38.The gas storage device of claim 36, wherein the grooves on the interiorsurface of the sidewall are oriented parallel to a longitudinal axis ofthe gas storage device.
 39. The gas storage device of claim 36, whereinthe diaphragm is cylindrical and comprises a diaphragm sidewall.
 40. Thegas storage device of claim 36, further comprising a vibration devicethat imparts a vibration when charging the gas storage device withhydrogen.